Method for manufacturing embroidered wallcovering

ABSTRACT

A method for manufacturing an embroidered wallcovering includes the following steps. Using a gravure press or cylinder screen press with water soluble inks, print patterns are printed on a base material. In the mean time of printing, the base material is heat dried. Thread patterns, which is corresponding to the print patterns, are embroidered onto the base material. The embroidery is done by a machine. Therefore, it is ideal for mass production. The embroidered wallcovering manufactured by this method has advantages of printed wallcovering and embroidery, and overcomes their disadvantages. The embroidered wallcovering manufactured by this method is environment friendly, and add dimension and quality to the wallcovering, thereby meeting the most demanding wall finish requirements.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a method for manufacturing a decorative wallcovering, and in particular to a method for manufacturing an embroidered wallcovering.

2. The Prior Arts

Conventional decorative wall cloths are classified into two categories: a fabric based wall cloth, which includes fabric coated with Polyvinyl Chloride (PVC), and a non-woven-material based wall cloth. A conventional method for manufacturing the non-woven-material based wall cloth includes the steps of printing print patterns on a non-woven material by a press and packaging the finished wall cloth. Because the non-woven material is breathable, it is easier to manufacture, paste on the wall, and is less likely to warp at the edges. However, the wall cloth is not suitable to emboss after printing. Thus, the conventional wall cloth can not provide three dimensional patterns. The decoration effect and the price level of the convention wall cloth are not high. Therefore, the conventional wall cloth can not satisfy the high level wall decoration.

Embroidery is a work of ornamental patterns in thread upon a foundation fabric using a needle, and provides decoration with raised images and vivid colors. Moreover, choosing various threads made of different materials can enhance the effect of the embroidery designs. Embroidery includes hand embroidery and machine embroidery. However, it is hard to control designs and color matching in a large scale machine embroidered work. The colors are difficult to adjust to present the realistic patterns in the large scale work. Thus, the machine embroidery is not used for wall decoration.

SUMMARY OF THE INVENTION

A primary objective of the present invention is to provide a method for manufacturing a wallcovering, which overcomes the disadvantage of the convention method that can not effectively present a design of volume on a two-dimensional surface or a delicate design.

In order to achieve the objective mentioned above, a method for manufacturing an embroidered wallcovering includes the steps of: printing print patterns on a base material by a gravure press or a cylinder screen press with water soluble inks and heat drying the base material in the meantime of printing; and embroidering thread patterns, which is corresponding to the print patterns, on the base material.

The method according to an embodiment of the present invention includes the steps of: (1) printing print patterns on a base material by a gravure press or a cylinder screen press with water soluble inks and heat drying the base material at a temperature of 100-250 degree Celsius in the meantime of printing; (2) trimming the dried and printed base material and cutting the base material into a semi-finish goods having a predetermined length and width; (3) embroidering thread patterns, which is corresponding to the print patterns, on the semi-finish goods to get an embroidered wallcovering; (4) trimming and smoothing a back of the wallcovering; (5) curling up the wallcovering into a roll and wrapping the roll in a shrink film.

The base material used in the aforementioned embroidered wallcovering can be chosen from a non-woven material, cotton textile, a fabric coated with PVC, or paper. The threads can be chosen from polyester threads, cotton threads, caddices, or metal threads, such as gold threads and silver threads. A thread count of the embroidery is under eighty thousand per meter in lengthwise direction.

The method for manufacturing an embroidered wallcovering according to the present invention may further include the step of decoration process. The decoration process includes sewing or attaching accessories onto the embroidered wallcovering for decoration. The accessories are chosen from metal strips, pearls, beads, quills, sequins, furs, rhinestones, etc.

A method for manufacturing an embroidered wallcovering according to another embodiment of the present invention includes the steps of: (1) using a non-woven material as a base material, printing print patterns on the base material by a gravure press or a cylinder screen press with water soluble inks, and heat drying the base material at a temperature of 100-250 degree Celsius in the meantime of printing; (2) trimming the dried and printed base material and cutting the base material into a semi-finish goods having a predetermined length and width; (3) embroidering thread patterns, which is corresponding to the print patterns, on the semi-finish goods to get an embroidered wallcovering, wherein threads can be polyester threads, cotton threads, caddices, or metal threads, such as gold threads and silver threads, and a thread count of the embroidery is under eighty thousand per meter in lengthwise direction; (4) operating a decoration process that sewing or attaching accessories onto the embroidered wallcovering, wherein the accessories are chosen from metal strips, pearls, beads, quills, sequins, furs, rhinestones, etc; (5) trimming and smoothing a back of the wallcovering; (6) curling up the wallcovering into a roll and wrapping the roll in a shrink film.

The characteristic of the method for manufacturing an embroidered wallcovering according to the present invention is combining printing with embroidery to create a new type of decorative wallcovering. Printing provides the base material of the wallcovering with vivid and colorful decorative print patterns. Embroidery provides the thread patterns of volume on a two-dimensional surface. Moreover, the print patterns match with the thread patterns, thereby improving the decoration level of the embroidery.

The base material can be chosen from any of materials suitable for printing, and the non-woven material is preferred. The threads can be chosen from regular threads used for embroidery. After printing and embroidering, the wallcovering may further include decorative accessories to enhance aesthetics.

The embroidered wallcovering manufactured by the method according to the present invention is embroidered by a machine. Thus, the method according to the present invention is ideal for mass production. The embroidered wallcovering manufactured by the method has the advantages of printed wallcovering and embroidery but does not have their disadvantages. The wallcovering is environment friendly, and add dimension and quality to the wallcovering, thereby meeting the most demanding wall finish requirements.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be apparent to those skilled in the art by reading the following detailed description of preferred embodiments thereof, with reference to the attached drawing, in which:

FIG. 1 is a flow chart showing a method for manufacturing an embroidered wallcovering.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a method for manufacturing an embroidered wallcovering according to the present invention includes printing, heat drying, cutting, embroidering, decorative processing, trimming, and packaging. A method for manufacturing an embroidered wallcovering according to a first embodiment of the present invention includes the following steps. (a) A non-woven material is chosen as a base material of a wall cloth. Using a gravure press with water soluble inks, print patterns are printed on the base material. In the mean time of printing, the base material passes an oven and is heat dried at a temperature of 180 degree Celsius. (b) The base material is cut into the semi-finish wall cloth having 10 m in length and 53 cm in width. (c) Thread patterns, which is corresponding to the print patterns, are embroidered on the semi-finish wall cloth to get an embroidered wall cloth. Polyester threads are used and a thread count of the thread patterns is under eighty thousand per meter in lengthwise direction. (d) A decoration process is operated, which pearls are sewed onto the embroidered wall cloth by gold threads or silver threads. (e) A back of the wall cloth is trimmed and smoothed. (f) The wall cloth is curled up into a roll and the roll is wrapped in a shrink film.

A method for manufacturing an embroidered wallcovering according to a second embodiment of the present invention includes the following steps. (a) Cotton textile is chosen as a base material of a wall cloth. Using a cylinder screen press with water soluble inks, print patterns are printed on the base material. In the mean time of printing, the base material passes an oven and is heat dried at a temperature of 250 degree Celsius. (b) The base material is cut into the semi-finish wall cloth having 10 m in length and 70 cm in width. (c) Thread patterns, which is corresponding to the print patterns, are embroidered onto the semi-finish wall cloth to get an embroidered wall cloth. Caddices are used and a thread count of the thread patterns is under eighty thousand per meter in lengthwise direction. (d) A decoration process is operated, which beads, sequins, furs, rhinestones are adhered onto the embroidered wall cloth. (e) A back of the wall cloth is trimmed and smoothed. (f) The wall cloth is curled up into a roll and the roll is wrapped in a shrink film.

A method for manufacturing an embroidered wallcovering according to a third embodiment of the present invention includes the following steps. (a) Paper is chosen as a base material of wallpaper. Using a gravure press with water soluble inks, print patterns are printed on the base material. In the mean time of printing, the base material passes an oven and is heat dried at a temperature of 100 degree Celsius. (b) The base material is cut into the semi-finish wallpaper having 10 m in length and 1 m in width. (c) Thread patterns, which is corresponding to the print patterns, are embroidered onto the semi-finish wallpaper. Cotton threads are used and a thread count of the thread patterns is under eighty thousand per meter in lengthwise direction. (d) A back of the wall cloth is trimmed and smoothed. (e) The wallpaper is curled up into a roll and the roll is wrapped in a shrink film.

Although the present invention has been described with reference to the preferred embodiments thereof, it is apparent to those skilled in the art that a variety of modifications and changes may be made without departing from the scope of the present invention which is intended to be defined by the appended claims. 

1. A method for manufacturing an embroidered wallcovering, comprising the steps of: (a) printing print patterns on a base material and heat drying the base material in the meantime of printing; and (b) embroidering thread patterns, which are corresponding to the print patterns, onto the base material.
 2. The method according to claim 1, further comprising the step of trimming and cutting the base material into a predetermined length and width after the step (a).
 3. The method according to claim 1, further comprising the step of trimming and smoothing a back of the embroidered base material after the step (b).
 4. The method according to claim 1, further comprising the step of curling up the base material into a roll and wrapping the roll in a shrink film after the step (b).
 5. The method according to claim 1, wherein the base material is printed by one of a gravure press and a cylinder screen press with water soluble inks.
 6. The method according to claim 1, wherein the base material is heat dried at a temperature of 100-250 degree Celsius.
 7. The method according to claim 1, wherein the base material is made of one of a non-woven material, cotton textile, a PVC coated fabric, and paper.
 8. The method according to claim 1, wherein a thread count of the thread patterns is under eighty thousand per meter in lengthwise direction.
 9. The method according to claim 1, wherein threads of the thread patterns are selected from the group consisting of polyester threads, cotton threads, caddices, metal threads, gold threads, and silver threads.
 10. The method according to claim 1, further comprising operating a decoration process to the base material after the step (b); wherein the decoration process comprises sewing or attaching accessories onto the base material.
 11. The method according to claim 10, wherein the accessories are selected from the group consisting of metal strips, pearls, beads, quills, sequins, furs, and rhinestones.
 12. A method for manufacturing an embroidered wallcovering, comprising the steps of: (a) using a non-woven material as a base material, printing print patterns on the base material by one of a gravure press and a cylinder screen press with water soluble inks, and heat drying the base material at a temperature of 100-250 degree Celsius in the meantime of printing; (b) trimming and cutting the base material into a predetermined length and width; (c) embroidering thread patterns, which are corresponding to the print patterns, onto the base material; wherein threads of the thread patterns are selected from the group consisting of polyester threads, cotton threads, caddices, metal threads, gold threads, and silver threads; and a thread count of the thread patterns is under eighty thousand per meter in lengthwise direction; (d) operating a decoration process to the base material; wherein the decoration process comprises sewing or attaching accessories onto the base material; and the accessories are selected from the group consisting of metal strips, pearls, beads, quills, sequins, furs, and rhinestones; (e) trimming and smoothing a back of the base material; (f) curling up the base material into a roll and wrapping the roll in a shrink film. 